Quick Start Guide. Allen-Bradley Parts

Transcription

1 Quick Start Guide Allen-Bradley Parts

2 Table of Contents

3 1 This quick start guide presents the basic information for the integration and operation of the 9/SERIES Standard Transfer Line package. More information is available on the 9/SERIES control family in these publications. Allen-Bradley Parts 1-1

4 The Allen-Bradley T-Line-9 software package is designed primarily for the drilling stations, transfer bars, or cross slides of a transfer line machine. The T-Line-9 package provides three major software segments. They are: Each of these T-Line-9 software segments are already loaded into your 9/SERIES control if it was purchased with the T-Line-9 option. An ODS backup project disk with the T-Line-9 AMP, PAL, and part program templates is included with this documentation set. Copies of this software are available at no cost through the Allen-Bradley motion control electronic BBS (216)

5 After unpacking your 9/SERIES Transfer Line control use the following flow chart as a guide to lead you through the integration process. Allen-Bradley Parts 1-3

6 The T-Line-9 Processor is uniquely equipped to minimize your system integration time and expense. The mounting, wiring, set-up, and manual or automatic sequencing of the operation are designed for quick system startup, and fast cycle times with reliable operation. The cycles for the transfer line are user-defined. With the transfer line option, there are 19 templates that perform drilling, boring and transfer line functions. You can customize pre-written templates by using QuickView. In QuickView, there is a screen for each cycle. On each screen there is a graphic representation of each cycle and prompts with which you customize the program. Once you enter the information through QuickView, the control generates a part program that functions like a cycle. 1-4

7 The T-Line-9 AMP and PAL is configured to pass spindle data out on remote I/O (remote I/O to PAL is discussed in chapter 2). Spindle direction and speed sent out through remote I/O must be properly handled with your PLC ladder logic. Spindle orients can also be performed using the T-Line-9 software which will pass the request to orient the spindle and send an orient location. The following commands in a part program sends spindle control information out through remote I/O: QuickView templates already have spindle control prompts for you to simply fill in the data. If desired, requests for spindle commands can be sent directly out connector TB3 on the processor. This connector uses an analog output signal ( 10vd) which can typically be wired directly to a spindle drive. To use TB3 for spindle control several AMP changes must be made. Important: It is the PLC programmers responsibility to assure that the spindle is functioning properly and turned on before the transferline machine begins executing its cycle. If you are using one of the solid tapping cycles the CNC must be controlling the spindle (using one of its servo connectors for feedback) for proper solid tapping orientation to occur. The feed to hard stop feature is used to position an axis against a mechanical stop and hold it against the stop with a programmed holding torque. This mechanical stop physically halts axis travel. The system installer determines the position of this hard stop based on mechanical consideration of the machine and the process currently being performed by the axis or transfer bar. Allen-Bradley Parts 1-5

8 Use the Adaptive Depth feature to enable an adaptive depth probe that monitors tool depth relative to the actual part surface. This feature allows a more flexible part mounting system (small changes to part size or part mounting do not require reprogramming of the station) and a less accurate machine drive system (tool position is relative to the part surface rather than the machine home). The system installer can determine in AMP if the position loop for moves that use the adaptive depth feature is closed by the axis encoder, or the adaptive depth probe. If the adaptive depth probe is selected the programmed depth can be programmed in the resolution available to the adaptive depth probe (this may be higher or lower then the actual axis resolution). You must use ODS to make AMP modifications to the T-Line-9 standard AMP to use this feature. Adaptive feedrate is a form of resolved motion force control. With this feature servo torque is controlled by the 9/SERIES CNC modifying the axis feedrate. Adaptive feedrate control will cause the servo to maintain a constant torque while cutting by varying the axis feedrate. The adaptive feed feature is helpful for machining processes where maintaining a constant feedrate is not as important as maintaining a constant cutting force. The adaptive feed feature also allows you to enter a feedrate range to prevent excessively low or high feedrates. The dry run function permits the checking of a part program to make sure that machine motions are correct. It is intended to be executed without the material or part mounted. The dry run function replaces all programmed feedrates with the maximum cutting feedrate. Jogging moves and moves that are programmed using rapid traverse (G00) are not effected by dry run. The Dry Run feature may be activated by using the {FRONT PANEL} softkey (page 1-10). You must be in set-up mode to active dry run with the software Front Panel. 1-6

9 This section is written to provide you with the essentials for operating the 9/SERIES control. For more details on the operation and programming of the 9/SERIES control refer to your 9/SERIES Mill Operation and Programming manual. Your removable operator panel connects to the 9/SERIES control through the removable operator panel interface assembly installed in the 9/SERIES Fiber Optic I/O ring as discussed in your 9/SERIES Integration and Maintenance Manual. The connection between removable operator panel and interface assembly is made via a 10 ft (max length) cable. This cable is provided with your removable operator panel. Attach the removable operator panel cable between the interface assembly connector CN5 and the 37 pin D shell connector on the front of your removable operator panel. You can attach or detach the operator panel at any time. We do not recommend, however, disconnecting this panel while in the middle of editing online or Patch AMP or while editing a part program. Exit these utilities before disconnecting your cable. Allen-Bradley Parts 1-7

10 We use the term softkey to describe the row of 7 keys at the bottom of the CRT. Each function is displayed on the CRT directly above the softkey. Softkey names are shown between the { } symbols in this manual. The control offers a variety of functions that can be initiated by using the softkeys. The operator panel has 5 softkeys whose function names are displayed in the softkey area at the bottom of the screen (lines see Figure 1.1). We often describe softkeys as being on a certain level, for example softkey level 3. We use the level of the softkey to determine the location or necessary path to reach that particular softkey function. For example, to get to a softkey on level 3, you must press a specific softkey on level 1, followed by a specific softkey on level 2. For a listing of all the softkeys and their respective levels, refer to appendix A of your Mill Operation and Programming Manual. Softkey level 1 is the initial softkey level the control displays at power-up. Softkey level 1 always remains the same and all other levels are referenced from softkey level 1. The softkeys on opposite ends of the softkey row have a specific use that remains standard throughout the different softkey levels. 1-8

11 Use the exit softkey { } on the far left to regress softkey levels. For example, if you are currently on softkey level 3 and you press the exit softkey, the softkeys change to the softkeys previously displayed on softkey level 2. When you press the exit softkey while holding down the shift key, the softkey display is returned to softkey level 1 regardless of the current softkey level. When more than 5 softkey functions are available on the same level, the control activates the continue { } softkey at the far right of the softkey area. When you press the continue softkey, the softkey functions change to the next set of softkeys on that level. Important: The continue softkey is not active when the number of softkey functions on that level does not exceed 5. For example: (softkey level 1) PRGRAM MANAGE OFFSET MACRO PARAM PRGRAM CHECK SYSTEM SUPORT When softkey level 1 is reached, the above set of softkeys is displayed. Pressing the continue softkey { } displays the remaining softkey functions on softkey level 1. (softkey level 1) FRONT PANEL ERROR MESAGE PASS- WORD SWITCH LANG The exit softkey is not displayed since the softkeys are already on softkey level 1. The softkey functions for level 1 and level 2 are explained in appendix A. Softkey functions for level 3, or higher, are explained in the sections that apply to their specific operations. To use a softkey function, press the plain, unmarked button directly below the description of the softkey function. Important: Some of the softkey functions are purchased as optional features. This manual assumes that all available optional features have been purchased for the machine. If an option is not purchased, the softkey is blank. Allen-Bradley Parts 1-9

12 Machine Tool Builders (MTB) Panel provides you with direct manual control over system functions such as jogging, spindle speed, and feedrate. Such functions are performed through the various switches and buttons on the panel face and are written by the system integrator. The 9/SERIES control offers a software MTB (machine tool builder) panel that performs many of the functions of an MTB panel. This feature uses softkeys instead of the normal switches and buttons of a panel. If the control use a standard MTB panel or some other custom panel, the requests for operations from that panel takes priority over the software front panel. This means that requests of the software MTB panel are ignored if another request is sent from a standard or custom MTB panel. The software front panel is disabled when your T-Line-9 is not in the set up mode. Set up mode is established through PAL (refer to chapter 2). 1-10

13 The software MTB panel can control these features: Allen-Bradley Parts 1-11

14 To use the software MTB panel feature, follow these steps: 1. From the main menu screen, press the {FRONT PANEL} softkey. (softkey level 1) PRGRAM MANAGE OFFSET MACRO PARAM PRGRAM CHECK SYSTEM SUPORT FRONT PANEL ERROR MESAGE PASS- WORD SWITCH LANG The Software MTB Panel screen displays the current status of the alterable features. Note if the control is not in setup mode (established through PAL) the {FRONT PANEL} softkey is disabled. SOFTWARE FRONT PANEL MODE SELECT: MDI RAPID TRAVERSE: OFF FEEDRATE OVR: 0% RAPID FEEDRATE OVR: 100% SPINDLE DIRECTION: CW SPINDLE SPEED OVR: 50% DRY RUN MODE: OFF BLOCK DELETE: OFF M-FUNC LOCK: OFF OPTIONAL STOP: OFF SINGLE BLOCK: OFF MIRROR IMAGE: AXIS INHIBIT: USE CURSOR FOR SELECTION JOG AXIS PRGRAM EXEC 2. Press the up or down cursor keys to select the function you want to change. The selected function appears in reverse video. 3. Alter the value of the function by pressing the left or right cursor keys (except for the Mirror Image and Axis Inhibit features). When you select the Mirror Image or Axis Inhibit features, the softkey names change to the axis names. Press the softkey that corresponds to the axis (or axes) that you want to assign to these features. 1-12

15 We assume that you have performed the steps to display the Software Front Panel screen. Make sure that the function selected on the Software Front Panel screen is not the Mirror Image or the Axis Inhibit features. 1. Press the {JOG AXIS} softkey. (softkey level 2) JOG AXIS PRGRAM EXEC This screen appears: E-STOP PROGRAM [mm] F MMPM Z S 0.0 R X T 0 C FILENAME SUB NAME MEMORY MAN STOP AXIS SELECT: X JOG SELECT: CONTINUOUS SPEED/MULTIPLY LOW HPG NUMBER 0 SET ZERO JOG AXIS + JOG AXIS 2. Select the axis, jog type, speed multiply value, and HPG (hand pulse generator) number (if HPG has been selected as the type of jog) by using the up and down cursor keys, and the left and right cursor keys to alter the value assigned to that function. See your Mill Operation and Programming manual for details on these values. 3. If the jog type is not HPG, then press the softkey that corresponds to the direction on the selected axis to jog (if HPG is the jog type then the direction of HPG rotation determines the direction to jog). Allen-Bradley Parts 1-13

16 4. If you want to shift the current work coordinate system to force the current tool position to be the zero point of the work coordinate system, press the {SET ZERO} softkey. The {SET ZERO} softkey does not function when the control is in handwheel mode. 9/230 controls, equipped with remote I/O, have the remote I/O circuitry and connection mounted directly on the processor board. Though the remote I/O link performs the same functions and is configured in the same manner for all the 9/SERIES controls, the installation and appearance is significantly different between processors. END OF CHAPTER 1-14

17 2 PAL is an acronym for Programmable Application Logic, and refers to an application specific ladder logic program that is continuously executed by the control s executive firmware. This ladder logic consists of PAL ladder language elements. These elements combine to form ladder rungs that make up PAL ladder modules. These ladder modules link together to form a PAL program. The PAL program coordinates and controls the I/O interface between the 9/SERIES control and the machine tool. Use PAL to sequence, operate, and monitor machine functions. Your transfer line control comes with an Allen-Bradley T-Line-9 standard transfer line PAL program already loaded into memory. This ladder program has all the I/O handled through Allen-Bradley remote I/O. If you decide to use the 9/SERIES fiber optic I/O ring a separate T-Line-9 PAL program is available at no cost through the Allen-Bradley electronic BBS (216) See page 2-6 for details on restoring an ODS project and downloading the PAL part program. The following table lists the I/O points available to/from the 9/SERIES T-Line-9 transfer line station. Access this I/O through either Allen-Bradley Remote I/O or through a digital I/O module on the 9/SERIES fiber optic I/O ring. Important: If you are using Allen Bradley remote I/O to handle your inputs and outputs you must assign a rack address and other remote I/O information to the control using AMP (parameters #140 to #144). By default the 9/SERIES is a full rack, addressed as rack 3, and communicating at 57.6K baud. The following descriptions assume you are using the T-Line-9 standard PAL and the part programs generated with the QuickView prompts have not been modified. Any modifications to the T-Line-9 Standard PAL or the part program could generate results other than those described here. Many PAL/remote I/O variables are eventually passed to or read from paramacro variables in the currently executing part program. For details on these paramacro variables see page Allen-Bradley Parts 2-1

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19 Allen-Bradley Parts 2-3

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21 Read this section if you desire an overview as to how the T-Line-9 standard PAL controls part program execution. This can be helpful if you decide you need to make minor modification to the T-Line-9 standard PAL. The T-Line-9 standard PAL automatically selects your part program (O00001 in this example) as the active program for execution. PAL tells the control to start executing this part program. The program executes at all times exept: when the control is in E-STOP, or the control is released for manual control using bit $RMI1.05 the selected program does not exist. When you first make the part program O00001 using the 9/SERIES part program editor, you must place the control either in the E-STOP state, edit the non active program, or release the control for manual operation using $RMI1.05. Exiting the editor and coming out of E-STOP or resetting the release for manual control bit to zero, starts the program executing. Assuming you have used QuickView transfer line prompts to generate a transfer line part program, the executing part program will test paramacro variables that monitor values passed from PAL. When PAL receives an input (either from remote I/O or through the 9/SERIES fiber optic I/O ring) that requests motion (for example to raise the transfer bar or return to a tool change location) it sets a paramacro variable true. When the part program detects the paramacro variable has gone true, it jumps to a specific portion of the part program that performs that operation. Certain variables only apply to certain cycles. For example if the I/O requests the transfer bar raise, and the control is executing a cross slide cycle, when PAL sets the paramacro variable to raise the transfer bar, that paramacro variable will not be used in the cross slide cycle so the request is ignored. If the I/O turns off the bit that initiated the motion, PAL will force a cycle stop operation (which halts programmed axis motion) and performs a control reset operation (which aborts the currently executing portion of the cycle and returns to the first block of the part program and again starts testing paramacro variables waiting for another request for motion). Allen-Bradley Parts 2-5

22 The following procedure describes the download procedure for restoring the transfer line standard PAL to the control. If for some reason PAL is lost on the control follow this procedure to re-install the ladder logic. Note you must first obtain an ODS backup of the T-Line-9 standard PAL from the Allen- Bradley Motion Control Division. This ODS backup project is included on floppy disk with this documentation or can be obtained using the Allen-Bradley motion control division electronic BBS (216) The transfer line project backup must be restored using a personal computer with the Allen-Bradley ODS software installed on its hard drive. Contact your Allen-Bradley sales office if you do not have a copy of the ODS software. Restore the project to ODS as described in your ODS reference manual (publication MCD-5.1). See the section titled Restoring a Backed up Project in the chapter titled Using ODS Project Management. The ODS workstation will copy the transfer line AMP, PAL, and part program templates into an ODS project titled TRANS230. On the control, you must configure port B for serial communication. The serial communication parameters of this port must correspond to those of the workstation. Refer to your 9/SERIES Operation and Programming manual for details on configuring the 9/SERIES serial port (the default for port B is configured for ODS communications). 1. Select the TRANS230 Project. The upper right portion of screen displays the currently active project name. If the transfer line project is not the active project: a. Press [F2] to select the Project Menu. b. Press [O] to open the transfer line project. c. Use the cursor keys to select the Transfer Line project and press [ENTER]. The workstation shows the active project as Transfer Line. 2. Connect your ODS workstation to the control using the serial cable discussed in chapter 6 of your ODS manual. ODS communication is performed through port B. The 9/230 processors only have one serial port. It is labeled port B. After you connect the workstation to the control: 1. Return to the main menu line of ODS. 2. Press [F3] to pull down the Application menu. 2-6

23 The workstation displays this screen: Proj: TRANS230 Appl: none Util: none F1 File F2 Project F3 Application F4 Utility F5 Configuration AMP PAL I/O Assignments Part Program Upload Download (A) (P) (I) (R) (U) (D) 3. Select the Download application. 4. Press [F4] to pull down the Utility menu. The workstation displays this screen: Proj: TRANS230 Appl: Download Util: none F1 File F2 Project F3 Application F4 Utility F5 Configuration Send AMP params Send PAL and I/O Send Part Program (A) (P) (R) 5. Select the Send PAL AND I/O utility. Allen-Bradley Parts 2-7

24 The workstation displays the Download Destination screen: Proj: TRANS230 Appl: Download Util: Send PAL and I/O F1 File F2 Project F3 Application F4 Utility F5 Configuration Download Destination Control with source (C) Control without source (W) Storage Device (S) 6. Select the Control with Source option. The workstation displays the message: Please place the control in ESTOP to download Place the control in E-STOP. When you press a key, the workstation displays this screen: Proj: TRANS230 Appl: Download Util: Send PAL and I/O F1 File F2 Project F3 Application F4 Utility F5 Configuration Downloading... Use ARROW keys or type in name. Press ENTER when done or ESC to cancel TRANS 2-8

25 7. Select the TRANS PAL file. The workstation displays this screen: Proj: TRANS230 Appl: Download Util: Send PAL and I/O F1 File F2 Project F3 Application F4 Utility F5 Configuration Pa Enter Password: [ ] Press <ESC> to leave unprotected The workstation asks you to create a password to protect the PAL source. A password is optional and is used to prevent unauthorized access to the PAL source on your machine. Pressing the <ESC> key will continue the download without password protecting your PAL source. After creating a password or pressing <ESC>, the workstation displays this screen: Proj: TRANS230 Appl: Download Util: Send PAL and I/O F1 File F2 Project F3 Application F4 Utility F5 Configuration Packing the PAL file for download Allen-Bradley Parts 2-9

26 The workstation displays this screen after it has successfully completed packing the PAL file for download: Proj: TRANS230 Appl: Download Util: Send PAL and I/O F1 File F2 Project F3 Application F4 Utility F5 Configuration Download in progress Percent transferred 50% The workstation continuously updates and displays the percentage of the file that has been transferred. When the download process is complete, the workstation displays this screen: Proj: TRANS230 Appl: Download Util: Send PAL and I/O F1 File F2 Project F3 Application F4 Utility F5 Configuration Download complete Press any key to continue... END OF CHAPTER 2-10

27 3 AMP is an acronym for Adjustable Machine Parameters. These are machine specific parameters that configure the physical details on your machine (such as motor types and drive configuration) and also define how your machine operates and is programmed (for example jog speeds, axis programming resolution, etc...). A standard transfer line AMP configured specifically for transfer line is available and already installed on your transfer line control. Minor adjustments to many of the AMP parameters can be made online using the controls operator panel and a utility called Patch AMP. Patch AMP is covered on page 3-2. The Offline Development System (ODS) software is used to develop and load AMP and PAL for your 9/SERIES control. The transfer line control already has a standard transfer line AMP and PAL loaded into memory. For most transfer line applications patch AMP is usually sufficient for customizing AMP for your machine. After using patch AMP to modify AMP we strongly recommend you upload your AMP changes to ODS for backup purposes. If you have major changes to AMP we recommend you use the ODS software instead of patch AMP. Backup the project to ODS from the control (as discussed on page 3-15) and edit that AMP file. Refer to your 9/SERIES AMP reference manual for details on editing AMP using ODS. Allen-Bradley Parts 3-1

28 Minor adjustments to many of the AMP parameters can be made online using the controls operator panel and a utility called Patch AMP. Patch AMP is accessed through the 9/SERIES softkey structure. Softkeys are the row of 7 keys found just below the CRT. Refer to page 1-8 for details on using the 9/SERIES softkeys. The function of each softkey is displayed on the CRT just above the corresponding key. Access to the {PATCH AMP} softkey is restricted to level zero password users (refer to your 9/SERIES Operation and Programming manual for details on access control using password protection). The 9/SERIES control will automatically power up at level zero password functions unless you have configured other passwords. We recommend you configure some password protection to prevent unauthorized access to the Patch AMP utility. Access the Patch AMP utility as follows: 1. Press the {SYSTEM SUPORT} softkey. (softkey level 1) PRGRAM MANAGE OFFSET MACRO PARAM PRGRAM CHECK SYSTEM SUPORT 2. Press the {AMP} softkey. (softkey level 2) PRGRAM MANAGE AMP DEVICE SETUP MONI- TOR TIME PARTS 3. Press the {PATCH AMP} softkey. The control will prompt you for an additional password to access the patch AMP utility. (softkey level 3) AXIS PARAM PATCH AMP UPDATE BACKUP UPLD/ DWNLD BACKUP AMP 4. The patch AMP password is the word LOCK. Type in LOCK using the operator panel keyboard and press the [TRANSMIT] key. The control will display the patch AMP utility screen. The AMP parameter QuickEdit number is in the left column. The value of that parameter is shown in the right column of the screen. 3-2

29 Use the search utility to quickly find the AMP parameter you need to edit. The following procedure outlines how to use the search utility: 1. Press the {SEARCH NUMBER} softkey. 2. Using the keyboard, type in the parameter number to search for and press the [TRANSMIT] key. The control will display the selected parameter in reverse video. If you enter a parameter number that can not be edited using patch AMP, the control displays the error message PARAMETER NUMBER NOT FOUND. Not all of the AMP parameter available can be edited using patch AMP. If you need to edit a parameter not in patch AMP you must use the ODS software. Refer to your 9/SERIES AMP reference manual for details on using ODS software for editing AMP. The control must be placed in E-STOP before you can modify patch AMP parameters. Use this procedure to edit parameters using the Patch AMP utility: 1. Using the cursor keys or the search utility place the cursor on the AMP parameter to be edited. The selected parameter is shown in reverse video. 2. Press the {REPLCE VALUE} softkey 3. Type in the new value of the parameter to be edited using the keyboard. Pressing the [TRANSMIT] key will change the parameters value on the CRT. 4. Repeat the above procedure until you have finished changing all the parameters you need to modify. When you are done, press the {UPDATE & EXIT} softkey. This will make the corrections to the controls AMP stored in RAM. You will be prompted to power down the control and power it back up. When power is re-applied to the control the new AMP values become active. After your machine is running the way you want it to and all patch AMP edits are completed, you should use the backup utility to write the AMP to flash memory (see page 3-13 ). Allen-Bradley Parts 3-3

30 The control displays a message on its operator panel indicating AMP HAS BEEN MODIFIED BY PATCH AMP. This message will appear at every power up. Clear the message using the [CAN] key on the operator panel. After you have completed all of your AMP changes and your machine is running properly we recommend you back AMP up to ODS. Once you have backed AMP up to ODS re-download that AMP file to remove the AMP HAS BEEN MODIFIED BY PATCH AMP message. Refer to your 9/SERIES AMP reference manual for details on backing up AMP to ODS. AMP values are configured using their QuickEdit numbers in patch AMP. The following table lists the most common QuickEdit parameter numbers that you will typically need to change for your specific transfer line control. The remaining AMP QuickEdit numbers are described in an appendix of your 9/SERIES AMP Reference manual. This table also lists the name of the parameter, it s default value (configured for your transfer line control), and the patch AMP value. The patch AMP values are always numeric values. Important: All patch AMP values are in millimeters. Units of time can be milliseconds, seconds, or minutes (as shown in the following table). The units used for patch AMP values is independent of how you configured AMP originally or the current mode of the control while setting the values. Use the Patch AMP Value in the table below to make the correlation between the numeric value and the AMP description. Shaded parameters are used for most applications. An L next to the parameter number indicates lathe only. Four digit AMP parameter numbers are per axis. The first digit being the axis number. Parameter Parameter Name Default Value Patch AMP Value 11 Standard Motor Table Values yes 0 No 1 Yes 32 PORT # FOR PARAMACRO EXTERNALS PORT B 0 PORT B 1 PORT A 66 Rapid Override in Dry Run True 0 False 1 True 69 PAL background interval 50 msec 30 to 10,000 msec 70 Dev. Detection Filter Time 20 msec 20 to 400 msec 71 Retract amount peck drilling mm to mm 73 Pullout angle, chamfered thrd 5.0 degrees 0.0 to 89.0 degrees 3-4

31 Parameter Parameter Name Default Value Patch AMP Value 74 Pullout dist, chamfered thrd thread leads to thread leads 76 Cycle clearance amount mm to mm 86 DAC monitor servo card 1 or 9/230 controls Disabled 0 Disabled 1 Enabled 87 DAC monitor servo card 2 Disabled 0 Disabled 1 Enabled 130 Number of Motors on 1st Board 2 1 to Number of Motors on 2nd Board 0 1 to DAC monitor servo card 3 Disabled 0 Disabled 1 Enabled 140 Adapter Baud Rate 57.6K K K K 141 Adapter Rack Number 3 0 to Adapter Rack Size FULL 0 1/4 rack 1 1/2 rack 2 3/4 rack 3 Full rack 143 Adapter Start Module Group SQ0 0 SQ0 1 SQ1 2 SQ2 3 SQ3 144 Adapter Last Rack Status Not Last Rack 0 Not Last Rack 1 Last Rack 204 Tool offset cancel Cancel Geom & Wear 0 Do not Cancel 1 Cancel Wear Only 2 Cancel Geom & Wear 206 Position tolerance for Skip mm to mm 207 Position tolerance for Skip mm to mm 208 Position tolerance for Skip mm to mm 209 Position tolerance for Skip mm to mm 402 Positioning ACC/DEC mode Linear 0 Exponential 1 Linear 405 Minimum feed reduction % 80 % 0 to 100 % 408 External decel speed (cutting) mm/sec to mm/sec 409 Corner override distance (DTC) mm to mm 410 Corner override distance (DFC) mm to mm 423 Feedrate for F mm/sec to mm/sec 424 Feedrate for F mm/sec to mm/sec 425 Feedrate for F mm/sec to mm/sec 426 Allen-Bradley Feedrate for F mm/sec Parts to mm/sec 427 Feedrate for F mm/sec to mm/sec 3-5

32 Parameter Parameter Name Default Value Patch AMP Value 428 Feedrate for F mm/sec to mm/sec 429 Feedrate for F mm/sec to mm/sec 430 Feedrate for F mm/sec to mm/sec 431 Feedrate for F mm/sec to mm/sec 600 Probe Length Compensation mm to mm 601 Probe Radius Compensation mm to mm 603 Approach Distance (R) mm to mm 604 Tolerance Band Distance (D) mm to mm 605 Approach Rate (E) mm/sec to mm/sec 606 Probe Rate (F) mm/sec to mm/sec 625 System Scan Time 10 ms 6 6 ms 8 8 ms ms ms ms ms ms ms ms ms ms ms ms 630 Probe Trigger Tolerance mm to mm 631 Depth Sensor Travel Limit mm to mm 632 Adaptive Depth Feedback Source From Probe 0 From Probe 1 From Axis 633 Controlling Axis for Probe None 0 None 65 A 66 B 67 C 85 U 86 V 87 W 88 X 89 Y 90 Z 634 Direction of Probe Trip Minus 1 Plus 1 Minus 3-6

33 Parameter Parameter Name Default Value 660 Deskew Master Servo Name None 0 None 65 A 66 B 67 C 85 U 86 V 87 W 88 X 89 Y 90 Z 661 Deskew Slave Servo Name None 0 None 65 A 66 B 67 C 85 U 86 V 87 W 88 X 89 Y 90 Z Patch AMP Value 662 Deskew Gain to Excess Skew Limit mm to mm 753 Max Tap Speed for rpm 0.0 to rpm Spindle 1, Gear Max Tap Speed for rpm 0.0 to rpm Spindle 1, Gear Max Tap Speed for rpm 0.0 to rpm Spindle 1, Gear Max Tap Speed for rpm 0.0 to rpm Spindle 1, Gear Max Tap Speed for rpm 0.0 to rpm Spindle 1, Gear Max Tap Speed for rpm 0.0 to rpm Spindle 1, Gear Max Tap Speed for rpm 0.0 to rpm Spindle 1, Gear Max Tap Speed for rpm 0.0 to rpm Spindle 1, Gear Gain for Spindle 1 Gear to Gain for Spindle 1 Gear to Gain for Spindle 1 Gear to Gain for Spindle 1 Gear to Gain for Spindle 1 Gear to Gain for Spindle 1 Gear to Allen-Bradley Gain for Spindle 1 Gear Parts to

34 Parameter Parameter Name Default Value Patch AMP Value 784 Gain for Spindle 1 Gear to Spindle DAC Output Ramping ON 0 Off 1 On 820 Voltage at Max for volts to volts Spindle 1, Gear Voltage at Max for volts to volts Spindle 1, Gear Voltage at Max for volts to volts Spindle 1, Gear Voltage at Max for volts to volts Spindle 1, Gear Voltage at Max for volts to volts Spindle 1, Gear Voltage at Max for volts to volts Spindle 1, Gear Voltage at Max for volts to volts Spindle 1, Gear Voltage at Max for Spindle 1, Gear volts to volts 851 Default Orient Direction, Spindle Spindle Marker Calibration, Spindle 1 Counter Clockwise 1 Counter Clockwise 2 Clockwise degrees to degrees 858 Orient Speed, spindle rpm 0.0 to rpm 860 Number of Gears Used, spindle to 8 gears 861 Spindle Deviation Tolerance, 100 % 0 to 100 % Spindle Default Orient Angle, spindle degrees to degrees 883 Acceleration Time for Spindle 1, Gear Accelerating Time for Spindle 1, Gear Acceleration Time for Spindle 1, Gear Acceleration Time for Spindle 1, Gear Acceleration Time for Spindle 1, Gear Acceleration Time for Spindle 1, Gear Acceleration Time for Spindle 1, Gear Minimum Spindle 1 Speed Gear seconds to seconds seconds to seconds seconds to seconds seconds to seconds seconds to seconds seconds to seconds seconds to seconds 0.0 rpm 0.0 to rpm 3-8

35 Parameter Parameter Name 901 Minimum Spindle 1 Speed Gear Minimum Spindle 1 Speed Gear Minimum Spindle 1 Speed Gear Minimum Spindle 1 Speed Gear Minimum Spindle 1 Speed Gear Minimum Spindle 1 Speed Gear Minimum Spindle 1 Speed Gear Maximum Spindle 1 Speed Gear Maximum Spindle 1 Speed Gear Maximum Spindle 1 Speed Gear Maximum Spindle 1 Speed Gear Maximum Spindle 1 Speed Gear Maximum Spindle 1 Speed Gear Maximum Spindle 1 Speed Gear Maximum Spindle 1 Speed Gear Dir. to Move Off Limit Switch Default Value Patch AMP Value 0.0 rpm 0.0 to rpm 0.0 rpm 0.0 to rpm 0.0 rpm 0.0 to rpm 0.0 rpm 0.0 to rpm 0.0 rpm 0.0 to rpm 0.0 rpm 0.0 to rpm 0.0 rpm 0.0 to rpm rpm 0.0 to rpm rpm 0.0 to rpm rpm 0.0 to rpm rpm 0.0 to rpm rpm 0.0 to rpm rpm 0.0 to rpm rpm 0.0 to rpm rpm 0.0 to rpm negative direction off switch Max % rated torque ( ) 200 % 0 to 200% 1 negative direction off switch 1 positive direction off switch Teeth on motor gear for vel FB 1 1 to 32,767 teeth Load inertia ratio 1 : 0 0 1:0 1 1:1 2 1:2 3 1:3 Teeth on lead screw for vel FB 1 1 to 32,767 Allen-Bradley Parts 3-9

36 Parameter Parameter Name Default Value Patch AMP Value Analog Servo Pos. Voltage volts to volts Software Overtravel Used False 0 False 1 True Maximum Servo Acceleration mm/s/s to mm/s/s Ve Integrator Discharge Rate 1 1 to 8 Analog Servo Neg. Voltage volts to volts Teeth on gear for pos. FB 1 1 to 32,767 teeth Teeth on lead screw for pos FB 1 1 to 32,767 teeth Hard Stop Holding Torque 10% 1 to 100% (nominal rated torque) Hard Stop Detection Torque 90% 1 to 300% (nominal rated torque) Feed Integral Torque Gain (for adaptive depth) Feed Proportional Torque Gain (for adaptive depth) Feedrate Acc/Dec Enable (for adaptive depth) to to Disabled 0 Disabled 1 Enabled Torque Filter Cutoff Frequency 200 Hz 10 to Hz External decel speed (posit.) mm/sec to mm/sec Maximum cutting feedrate mm/sec to mm/sec 3-10

37 Parameter Parameter Name Default Value Patch AMP Value ACC/DEC ramp mm/s/s to mm/s/s Rapid feedrate for positioning mm/sec to mm/sec Velocity step for ACC/DEC mm/sec to mm/sec Home Calibration mm to mm Axis Position after Homing mm to mm Positive Software Overtravel mm to mm Negative Software Overtravel mm to mm Reversal Error Compensation mm to mm Home Speed from Limit Switch mm/sec to mm/sec Servo Position Loop Type Closed Loop 0 Open Loop for Analog Only 1 Closed Loop 2 ZFE Closed Loop 3 Servo Off 4 Servo Detached 5 Depth Probe Velocity Feedback Type INC Encoder A/B/Z (Z<A) Velocity Feedback Counts/Rev 24,000 1 to 65,536 Position Feedback Type INC Encoder A/B/Z (Z<A) 0 No Feedback 1 ABS Encoder 2 INC Encoder U/V/W channel 3 INC Encoder A/B/Z (Z<A) 4 INC Encoder A/B/Z (Z>A) 0 No Feedback 1 ABS Encoder on Dig. Mod. 2 INC Encoder U/V/W channel on Dig. Mod. 3 INC Encoder A/B/Z (Z<A) 4 INC Encoder A/B/Z (Z>A) Allen-Bradley Parts 3-11

38 Parameter Parameter Name Default Value Patch AMP Value Position Feedback Counts/Rev 24,000 1 to 65,536 Maximum Motor Speed 2000 rpm 0 to 99,999 rpm Lead screw thread pitch mm to mm Sign of Position Feedback Plus 1 Plus 1 Minus Sign of Velocity Feedback Plus 1 Plus 1 Minus Peak Current as a % of RMS 200% % % Max % rated torque (+) 200 % 0 to 200% Feed Forward Percent 0 % 0 to 100% Torque Offset Percentage 0 % 0 to 100% Torque Offset Direction Minus 1 Plus 1 Minus Initial Gain of Position Loop to Position Loop Gain Break Ratio to Gain Break Point mm to mm Inposition Band mm to mm Feedrate Suppression Point mm to mm 3-12

39 Parameter Parameter Name Default Value Patch AMP Value Excess Error mm to mm Steady State Band 7 1 to 32,767 Servo Amplifier Type No Servo Amplifier 0 No Servo Amplifier 1 3 servo (8520 AA12) :CNA1 2 3 servo (8520 AA12) :CNA2 3 3 servo (8520 AA12) :CNA3 4 2 servo (8520 AA6 :CNA1 5 2 servo (8520 AA6 :CNA2 6 single axis (8520 AA21) 8 3 servo (8520 AA12), both modules 9 2 servo (8520 AA6), both modules 10 2 of 3 servo (8520-AA12) :CNA of 3 servo (8520 AA12) :CNA of 3 servo (8520-AA12) :any 13 1 of 2 servo (8520 AA6) :either Velocity Integral Gain to 32,768 Velocity proportional gain to 65,536 When you modify AMP using patch AMP you are editing a copy of AMP that is in volatile memory (maintained by a supercap or lithium battery). Once you have completed all of your modifications to AMP you should write AMP to flash memory. Flash memory is a non-volatile area of memory that maintains AMP even if the Supercap or lithium battery loses its charge. To save a copy of your AMP changes off of the control we recommend backing up your final AMP configuration by uploading to your ODS workstation. Refer to your AMP reference manual for details on uploading your AMP file from the control. Use the following procedure to write AMP to flash memory: 1. Press the {SYSTEM SUPORT} softkey. (softkey level 1) PRGRAM MANAGE OFFSET MACRO PARAM PRGRAM CHECK SYSTEM SUPORT Allen-Bradley FRONT PANEL ERROR MESAGE PASS- Parts WORD SWITCH LANG 3-13

40 2. Press the {AMP} softkey. (softkey level 2) PRGRAM MANAGE AMP DEVICE SETUP MONI- TOR TIME PARTS 3. Press the {UPDATE BACKUP} softkey. (softkey level 3) AXIS PARAM PATCH AMP UPDATE BACKUP UPLD/ DWNLD BACKUP AMP The control displays this screen when the {UPDATE BACKUP} softkey is pressed: STORE TO BACKUP AMP AXIS CALIBRATION SELECT OPTION USING THE UP/DOWN ARROW TO BACKUP FROM BACKUP 4. Use the up or down cursor keys to highlight AMP option on the screen. 5. To backup information to the control s flash memory from the control s RAM memory, press the {TO BACKUP} softkey. The AMP currently in RAM that you have either downloaded from ODS or modified using patch AMP is copied from the control s RAM to the control s flash memory. 3-14

41 If AMP in RAM becomes corrupted (for example if you made incorrect modifications using patch AMP) you can restore AMP from flash memory and overwrite the AMP in RAM by pressing the {FROM BACKUP} softkey (assuming AMP in flash is not also corrupted). This will copy the AMP from flash into the controls RAM. The default transfer line AMP is loaded into flash memory when the control is shipped from Allen-Bradley. The control displays the message PLEASE POWER DOWN AND RESTART when you copy AMP from flash memory to the controls RAM. The control must be turned off and then on again after the information is backed up from flash memory to RAM. The following procedure describes the download procedure for restoring the transfer line standard AMP to the control. If for some reason AMP is lost on the control, follow this procedure to re-install the AMP values. Note you must first obtain an ODS backup of the T-Line-9 standard AMP from the Allen- Bradley Motion Control Division. This ODS backup project is included on floppy disk with this documentation or can be obtained using the Allen-Bradley motion control division electronic BBS (216) The transfer line project backup must be restored using a personal computer with the Allen-Bradley ODS software installed on its hard drive. Contact your Allen-Bradley sales office if you do not have a copy of the ODS software. Restore the project to ODS as described in your ODS reference manual (publication MCD-5.1). See the section titled Restoring a Backed up Project in the chapter titled Using ODS Project Management. The ODS workstation will copy the transfer line AMP, PAL, and part program templates from the ODS backup project titled TRANS230. On the control, you must configure port B for serial communication. The serial communication parameters of this port must correspond to those of the workstation. Refer to your 9/SERIES Operation and Programming manual for details on configuring the 9/SERIES serial port (the default for port B is already configured for ODS communications). 1. Select the TRANS230 Project. The current project name is shown in the upper right portion of screen. If the transfer line project is not the active project: a. Press [F2] to select the Project Menu. b. Press [O] to open the transfer line project. c. Use the cursor keys to select the Transfer Line project and press [ENTER]. The workstation shows the active project as Transfer Line. Allen-Bradley Parts 3-15

42 2. Connect your ODS workstation to the control using the serial cable discussed in chapter 6 of your ODS manual. The 9/230 and T-LINE 9 processors only have one serial port. It is labeled and configured as Port B. After you connect the workstation to the control: 1. Return to the main menu line of ODS. 2. Press [F3] to pull down the Application menu. The workstation displays this screen: Proj: TRANS230 Appl: none Util: none F1 File F2 Project F3 Application F4 Utility F5 Configuration AMP PAL I/O Assignments Part Program Upload Download (A) (P) (I) (R) (U) (D) 3. Select the Download application. 4. Press [F4] to pull down the Utility menu. The workstation displays this screen: Proj: TRANS230 Appl: Download Util: none F1 File F2 Project F3 Application F4 Utility F5 Configuration Send AMP params Send PAL and I/O Send Part Program (A) (P) (R) 3-16

43 5. Select the Send AMP parameters utility. The workstation displays the Download Destination screen: Proj: TRANS230 Appl: Download Util: Send AMP params F1 File F2 Project F3 Application F4 Utility F5 Configuration Download Destination Control Storage Device (C) (S) 6. Select the Control option. The workstation displays the message: Please place the control in ESTOP to download Place the control in E-STOP. When you press any key, the workstation displays this screen: Proj: TRANS230 Appl: Download Util: Send AMP params F1 File F2 Project F3 Application F4 Utility F5 Configuration Downloading... Use ARROW keys or type in name. Press ENTER when done or ESC to cancel 1_AXIS 2_AXIS Allen-Bradley Parts 3-17

44 7. Select the transfer line AMP file to download and press [ENTER]. Select 1_AXIS for single axis applications, or 2_Axis for two axis applications. The workstation displays this screen: Proj: TRANS230 Appl: Download Util: Send AMP params F1 File F2 Project F3 Application F4 Utility F5 Configuration Download in progress Percent transferred 50% The workstation continuously updates and displays the percentage of the file that has been transferred. When the download process is complete, the workstation displays the message: DOWNLOAD COMPLETE The control displays the message: PLEASE POWER DOWN AND RESTART 8. After downloading AMP, you must turn off the control and then turn it on again. The new AMP values are then used for software execution. END OF CHAPTER 3-18

45 4 The 9/SERIES T-Line-9 system comes with a set of part program templates for a wide variety of transfer line applications including: These part program templates are loaded into control memory before your control ships from Allen-Bradley. These part program templates are stored by the control in a volatile memory area (requires power to be maintained). Depending on the length of time between when the control is shipped to you, and when you first power up the control, these part program templates may not be available, especially if the system doesn t include the battery memory backup option. Allen-Bradley Parts 4-1

46 This document only discusses how to create and modify your transfer line part programs using the templates provided. For details on the operation of any specific cycle refer to your mill operation and programming manual. This manual is organized into these sections: Though your transfer line control comes with part program templates, you must still customize that template into a working part program for your specific machine application. The 9/SERIES QuickView prompts are designed to work with the part program templates to enable you to modify your program template easily. QuickView includes a graphical representation of the cycle, like the example shown here: SINGLE AXIS TRANSFER CYCLE X2 F1 F1 I X1 TRANSFER VELOCITY F1 FULL ADVANCE POSITION X1 FULL RETURN POSITION X2 HARD STOP SENSE ZONE I STORE 1. Before you begin editing a part program, the control needs to be in E-stop or the bit for Stop Program Cycle for Local Manual Control must be set. 4-2

47 2. Press the {PRGRAM MANAGE} softkey. The program directory screen is displayed. (softkey level 1) PRGRAM MANAGE OFFSET MACRO PARAM QUICK CHECK SYSTEM SUPORT FRONT PANEL ERROR MESAGE PASS- WORD SWITCH LANG SELECTED PROGRAM: DIRECTORY PAGE 1 OF 1 NAME SIZE COMMENT 0 FILES 150 METERS FREE ACTIVE PRGRAM EDIT PRGRAM RESTRT PRGRAM DISPLY PRGRAM COPY PRGRAM Allen-Bradley Parts 4-3

48 3. Type 1 for the selected program name and then press {EDIT PRGRAM}. The control names the created part program O (softkey level 2) ACTIVE PRGRAM EDIT PRGRAM RESTRT PRGRAM DISPLY PRGRAM COPY PRGRAM VERIFY PRGRAM PRGRAM COMENT DELETE PRGRAM RENAME PRGRAM INPUT DEVICE REFORM MEMORY INSERT : EDIT FILE : O00001 POS 1*1 MODE : CHAR MODIFY INSERT BLOCK DELETE BLOCK TRUNC DELETE CH/WRD EXIT EDITOR 4-4

49 4. From the edit menu, press the {QUICK VIEW} softkey. (softkey level 3) MODIFY BLOCK INSERTDELETE BLOCK TRUNC DELETE CH/WRD EXIT EDITOR STRING RENUM SEARCH PRGRAM MERGE PRGRAM QUICK VIEW CHAR/ WORD DIGITZ E 5. The softkey functions will change to those indicated below. (softkey level 4) QPATH+ PROMPT GCODE PROMPT MILL PROMPT TRNSFR PROMPT PLANE SELECT Allen-Bradley Parts 4-5